EP3124098B1 - Monolithic separation membrane structure and method for producing same - Google Patents

Monolithic separation membrane structure and method for producing same Download PDF

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Publication number
EP3124098B1
EP3124098B1 EP15763806.5A EP15763806A EP3124098B1 EP 3124098 B1 EP3124098 B1 EP 3124098B1 EP 15763806 A EP15763806 A EP 15763806A EP 3124098 B1 EP3124098 B1 EP 3124098B1
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EP
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Prior art keywords
support layer
silica
separation membrane
magnesia
component
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German (de)
English (en)
French (fr)
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EP3124098A1 (en
EP3124098A4 (en
Inventor
Makoto Teranishi
Makiko ICHIKAWA
Hideyuki Suzuki
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NGK Insulators Ltd
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NGK Insulators Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D63/00—Apparatus in general for separation processes using semi-permeable membranes
    • B01D63/06—Tubular membrane modules
    • B01D63/066—Tubular membrane modules with a porous block having membrane coated passages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/01—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with flat filtering elements
    • B01D29/05—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with flat filtering elements supported
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/0093—Making filtering elements not provided for elsewhere
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0001—Making filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0039—Inorganic membrane manufacture
    • B01D67/0041—Inorganic membrane manufacture by agglomeration of particles in the dry state
    • B01D67/00411—Inorganic membrane manufacture by agglomeration of particles in the dry state by sintering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B01D69/108—Inorganic support material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/12—Composite membranes; Ultra-thin membranes
    • B01D69/1214—Chemically bonded layers, e.g. cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/02—Inorganic material
    • B01D71/021—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/02—Inorganic material
    • B01D71/024—Oxides
    • B01D71/025—Aluminium oxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D71/02—Inorganic material
    • B01D71/024—Oxides
    • B01D71/027—Silicium oxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/02—Inorganic material
    • B01D71/028—Molecular sieves
    • B01D71/0281—Zeolites
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111—Fine ceramics
    • C—CHEMISTRY; METALLURGY
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    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
    • C—CHEMISTRY; METALLURGY
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0003—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof containing continuous channels, e.g. of the "dead-end" type or obtained by pushing bars in the green ceramic product
    • C—CHEMISTRY; METALLURGY
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006—Honeycomb structures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2323/00—Details relating to membrane preparation
    • B01D2323/12—Specific ratios of components used
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2325/00—Details relating to properties of membranes
    • B01D2325/24—Mechanical properties, e.g. strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2325/00—Details relating to properties of membranes
    • B01D2325/30—Chemical resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0039—Inorganic membrane manufacture
    • B01D67/0046—Inorganic membrane manufacture by slurry techniques, e.g. die or slip-casting
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
    • C04B2111/00801—Membranes; Diaphragms
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/36—Glass starting materials for making ceramics, e.g. silica glass
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0051—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity
    • C04B38/0054—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity the pores being microsized or nanosized

Definitions

  • the present invention relates to a monolithic separation membrane structure and to a method of manufacturing the same.
  • a monolithic separation membrane structure which typically includes a substrate that has a plurality of through holes, a support layer that is formed on an inner surface of the through holes, and a separation membrane that is formed on an inner surface of the support layer (reference to Patent Literature 1).
  • Patent Literature 1 a method is proposed in which titania is added as a binding agent to the support layer for the purpose of enhancing the strength and chemical resistance of the support layer.
  • the present invention is proposed based on the situation described above, and has the purpose of providing a monolithic separation membrane structure that enables enhancement to the strength of a support layer and of providing a method of manufacture for the same.
  • the monolithic separation membrane structure according to the present invention includes the features set forth in claim 1.
  • the method for manufacturing a monolithic separation membrane structure according to the present invention includes the features set forth in claim 5.
  • the present invention enables the provision of a monolithic separation membrane structure that enables enhancement to the strength of the support layer, and a method of manufacture for the same.
  • the term "monolithic” is a concept that denotes a shape that includes a plurality of through holes formed in a longitudinal direction, and includes a honeycomb shape.
  • FIG. 1 is a perspective view illustrating a monolithic separation membrane structure.
  • FIG. 2 illustrates a sectional view along the line A - A of FIG. 1 .
  • FIG. 3 illustrates a sectional view along the line B - B of FIG. 2
  • the monolithic separation membrane structure 100 includes a monolithic substrate 200 and a separation membrane 300.
  • the monolithic substrate 200 includes a substrate main body 210, a first seal portion 220 and a second seal portion 230.
  • the substrate main body 210 is a porous body.
  • the substrate main body 210 is formed as a circular cylinder.
  • the length of the substrate main body 210 in a longitudinal direction is 150 to 2000 mm, and the diameter of the substrate main body 210 in the short width direction is 30 to 220 mm.
  • the diameter of the substrate main body 210 in the short width direction is 30 to 220 mm.
  • the substrate main body 210 has a first end surface 210a, a second end surface 210b and a side surface 210c.
  • the first end surface 210a is provided opposite to the second end surface 210b.
  • the side surface 210c is connected to the outer edge of the first end surface 210a and the second end surface 210b.
  • the substrate main body 210 includes a substrate 211, a first support layer 212 and a second support layer 213.
  • the substrate 211 is formed as a circular cylinder.
  • a plurality of through holes TH is formed in the substrate 211.
  • the through holes TH pass through the substrate 211 from the first end surface 210a to the second end surface 210b.
  • the sectional shape of the through holes TH is circular.
  • the inner diameter of the through holes TH is 1 to 5 mm.
  • the inner diameter of a cell C as described hereafter can be enlarged by enlarging the inner diameter of the through holes TH.
  • the substrate 211 is formed by a porous material.
  • the porous material that configures the substrate 211 includes use of a ceramic, metal, resin, or the like. In particular, use of a porous ceramic is preferred.
  • the aggregate particles used in relation to the porous ceramic material include alumina (Al 2 O 3 ), titania (TiO 2 ), mullite (Al 2 O 3 ⁇ SiO 2 ), potsherd, and cordierite (Mg 2 Al 4 Si 5 O 18 ), and in particular, alumina is preferred in light of ease of availability, formation of a stable clay and anticorrosive properties.
  • the substrate 211 may include an inorganic binder in addition to the porous material.
  • the inorganic binder may include at least one of titania, mullite, easily sinterable alumina, silica, glass frits, clay minerals, easily sinterable cordierite.
  • the porosity of the substrate 211 may be 25 to 50%.
  • the average pore diameter of the substrate 211 may be 5 micrometers to 25 micrometers and the average particle diameter of the porous material that configures the substrate 211 may be 5 micrometers to 100 micrometers.
  • the term "average particle diameter” is the arithmetic means for the maximum diameter of 30 measured particles that are measured by cross sectional micro-structure observation by use of a scanning electron microscope (SEM).
  • the first support layer 212 is formed on the inner surface 211S of the through holes TH of the substrate 211.
  • the first support layer 212 has a tubular configuration.
  • the first support layer 212 is formed from a porous ceramic material. More specifically, the first support layer 212 includes an aggregate material, an inorganic binder and a sintering additive.
  • the aggregate material of the first support layer 212 includes alumina as a principal component.
  • the inorganic binder of the first support layer 212 includes titania as a principal component.
  • the titania particles in the inorganic binder form a binding neck that covers at least a portion of the alumina particles in the aggregate material.
  • the sintering additive of the first support layer 212 includes at least one of silica and magnesia as a main component.
  • the silica or magnesia in the sintering additive promotes sintering of the green body during sintering of the green body for the first support layer 212.
  • the silica component or magnesia component is present in the interface of the titania particles and the alumina particles or between the titania particles. In this manner, the strength of the first support layer 212 is adapted to be enhanced by the distribution of the silica component or the magnesia component in proximity to the inorganic binder.
  • the titania concentration in the first support layer 212 is at least 5 wt% to no more than 40 wt%, and is preferably at least 10 wt% to no more than 30 wt%.
  • the silica concentration in the first support layer 212 is at least 0.1 wt% to no more than 6 wt%, and is preferably at least 0.25 wt% to no more than 6 wt%.
  • the magnesia concentration in the first support layer 212 is at least 0.1 wt% to no more than 5 wt%, and is preferably at least 0.5 wt% to no more than 5 wt%.
  • the concentration of the sintering additive is calculated as sintering additive amount/(aggregate material amount + inorganic binder amount) x 100.
  • the concentration of each component in the present embodiment is measured by use of energy dispersive x-ray spectroscopy (EDS).
  • a composition X includes a substance Y "as a main component" means that in relation to the total of the composition X, the substance Y preferably occupies at least 60 wt%, more preferably at least 70 wt% and still more preferably at least 90 wt%.
  • the thickness of the first support layer 212 in a direction vertical (hereafter referred to as the "radial direction") to the central axis of the through holes TH is 100 micrometers to 300 micrometers.
  • the strength of the first support layer 212 is enhanced by addition of at least one of silica and magnesia as described above, the surface area of the separation membrane 300 per filter can be increased by decreasing the thickness of the first support layer 212.
  • the porosity of the first support layer 212 may be configured as 5% to 60%.
  • the average pore diameter of the first support layer 212 may be configured as 0.005 micrometers to 5 micrometers, and thereby is smaller than the average pore diameter of the substrate 211.
  • the second support layer 213 is formed on the inner surface 212S of the first support layer 212.
  • the second support layer 213 has a tubular configuration.
  • the second support layer 213 is composed of a porous ceramic material. More specifically, the second support layer 213 includes an aggregate material and a sintering additive.
  • the aggregate material of the second support layer 213 includes alumina as a main component.
  • the sintering additive of the second support layer 213 includes at least one of silica and magnesia as a main component. The silica and magnesia promote sintering of the green body when the green body for the second support layer 213 is sintered.
  • the silica component and magnesia component of the sintering additive is distributed between the alumina particles of the aggregate material.
  • the silica concentration in the second support layer 213 is preferably at least 0.01 wt% to no more than 40 wt%.
  • the second support layer 213 includes magnesia as a sintering additive the magnesia concentration in the second support layer 213 is at least 0.01 wt% to no more than 40 wt%.
  • the silica concentration in the second support layer 213 is at least 0.01 wt% to no more than 10 wt%, and the magnesia concentration in the second support layer 213 is at least 0.01 wt% to no more than 10 wt%.
  • the thickness of the second support layer 213 in the radial direction is 1 micrometer to 40 micrometers.
  • the porosity of the second support layer 213 may be configured as 5% to 40%.
  • the average pore diameter of the second support layer 213 may be configured as 0.005 micrometers to 2 micrometers and thereby be smaller than the average pore diameter of the first support layer 212.
  • the first seal portion 220 covers the whole surface of the first end surface 210a and a portion of the side surface 210c.
  • the first seal portion 220 controls the direct permeation, from the first end surface 210b to the substrate main body 210, of the mixed fluid to be filtered that enters the through holes TH.
  • the first seal portion 220 is formed so that a barrier is not formed in relation to the input port for the cell C that is described below.
  • the material that configures the first seal portion 220 includes use of glass, metal or the like. However, glass is preferred in light of the adaptability with the thermal expansion coefficient of the substrate main body 210.
  • the second seal portion 230 covers the whole surface of the second end surface 210b and a portion of the side surface 210c.
  • the second seal portion 230 controls the direct permeation, from the second end surface 210b to the substrate main body 210, of the mixed fluid that flows out of the through holes TH.
  • the second seal portion 230 is formed so that a barrier is not formed in relation to the output port for the cell C.
  • the second seal portion 230 may be composed of the same material as the first seal portion 220.
  • the separation membrane 300 has a tubular configuration.
  • the separation membrane 300 is arranged in the through holes TH.
  • the separation membrane 300 is formed on an inner surface 213S of the second support layer 213.
  • the inner side of the inner surface 300S of the separation membrane 300 forms a cell C for flow of the mixed fluid.
  • the inner diameter of the cell C in the radial direction may be configured as 0.5 mm to 3.5 mm.
  • the inner diameter of the cell C affects the separation efficiency and the strength under internal pressure.
  • the inner diameter of the cell C may be increased by decreasing the thickness of the first support layer 212 or by increasing the inner diameter of the through hole TH of the substrate 211.
  • the surface area of the surface 300S of the separation membrane 300 can be increased by increasing the inner diameter of the cell C.
  • the separation membrane 300 is preferably composed of an inorganic material, metal or the like.
  • the inorganic material of the separation membrane 300 includes zeolite, carbon, silica, or the like.
  • the metal material used in relation to the separation membrane 300 includes palladium, or the like.
  • the separation membrane 300 is configured as a zeolite membrane, the zeolite may be used that exhibits a crystal structure such as LTA, MFI, FER, FAU, DDR, CHA, BEA, or the like.
  • the separation membrane 300 is a DDR zeolite membrane, use is particularly adapted in relation to a gas separation membrane for selective separation of carbon dioxide.
  • the thickness of the separation membrane 300 in the radial direction is preferably no more than 10 micrometers, and more preferably no more than 5 micrometers.
  • the porosity of the separation membrane 300 may be configured as 0% to 20%.
  • the average pore diameter of the separation membrane 300 may be configured as 0.1 nanometer to 1 micrometer and thereby be smaller than the average pore diameter of the first support layer 212 or the second support layer 213.
  • a ceramic body including a porous material is used to form the green body for the substrate 211 that exhibits a plurality of through holes TH.
  • the method of forming the green body for the substrate 211 includes use of an extrusion molding method using a vacuum extrusion molding device, in addition to press molding method or slip cast method.
  • the substrate 211 is formed by firing (for example, 900 degrees C to 1600 degrees C, 0 hours to 100 hours) the green body for the substrate 211.
  • a slurry for the first support layer is prepared by adding at least one of silica and magnesia as a sintering additive, an organic binder, a pH adjusting agent and a surface active agent to titania that is used as the inorganic binding agent and alumina that is used as the aggregate material.
  • the green body for the first support layer 212 is formed by a filtration method by use of the slurry for the first support layer. More specifically, a green body for the first support layer 212 is deposited on the inner surface 211S of the through holes TH by using a pump to draw the slurry for the first support layer from the inner surface 210c of the substrate 211 while supplying the slurry to the through holes TH.
  • the first support layer 212 is formed by firing (for example, 900 degrees C to 1600 degrees C, 0.5 hours to 100 hours) the green body for the first support layer 212.
  • a slurry for the second support layer is prepared by adding at least one of silica and magnesia as a sintering additive, an organic binder, a pH adjusting agent and a surface active agent to alumina that is used as the aggregate material.
  • the green body for the first support layer 212 is formed by a filtration method by use of the slurry for the second support layer. More specifically, a green body for the second support layer 213 is deposited on the inner surface 212S of the first support layer 212 by using a pump to draw the slurry for the second support layer from the inner surface 210c of the substrate 211 while supplying the slurry to the inner side of the first support layer 212.
  • the second support layer 213 is formed by firing (for example, 900 degrees C to 1600 degrees C, 0.5 hours to 100 hours) the green body for the second support layer 213.
  • the separation membrane 300 is formed on the inner surface 213S of the second support layer 213.
  • the method for forming the separation membrane 300 may include use of a suitable method that is adapted to the type of the separation membrane 300.
  • a seeding step using a flow-down method is performed in sequence with a sol hydrothermal synthesis step and a heating step for removing the structure directing agent.
  • a seeding step for a silica sol solution is performed in sequence with a firing step (150 degrees C to 800 degrees C, 0 hours to 100 hours).
  • a coating step for a precursor solution is performed in sequence with a firing step (150 degrees C to 800 degrees C, 0 hours to 100 hours).
  • a monolithic separation membrane structure according to Samples No. 1 to No. 14 is prepared as described below. Sample Nos. 1, 2 and 8 are outside the terms of the claims.
  • a ceramic body is prepared by adding 10 parts by mass of glass frit to 100 parts by mass of alumina having an average particle diameter of 10 micrometers, then water, a dispersing agent and a thickener are added, and the mixture is kneaded.
  • a green body for the substrate that includes a plurality of through holes is prepared by extrusion molding of the prepared ceramic body.
  • the substrate is prepared by firing the green body for the substrate (1250 degrees C, 1 hour).
  • a slurry for the first support layer is prepared by adding an organic binder, a pH adjusting agent and a surface active agent to titania that is used as the inorganic binding agent and alumina that is used as the aggregate material. Then as shown in Table 1, silica powder is added as a sintering additive to Samples 3 to 8, 10 and 11, a silica sol is added as a sintering additive to Samples 12 to 14, and magnesia powder is added as a sintering additive to Sample 9. The respective added amounts of silica powder, silica sol and magnesia powder to the total weight of alumina and titania are shown in Table 1.
  • a green body for the first support layer is deposited on the inner surface of the through holes by using a pump to draw the slurry for the first support layer from the inner surface of the substrate while supplying the slurry to the through holes.
  • the green body for the first support layer is fired (1250 degrees C, 1 hour).
  • a slurry for the second support layer is prepared by adding magnesium acetate as a sintering additive, an organic binder, a pH adjusting agent and a surface active agent to alumina that is used as the aggregate material.
  • the green body for the second support layer is fired (1250 degrees C, 10 hours).
  • Each sample was placed into a separation device, and water under pressure was passed through an inner portion of the DDR membrane (that is to say, the cell) to thereby gradually increase the applied pressure until fracture of each sample.
  • Table 1 states the fracture strength of each sample as applied pressure (MPa) at time of fracture.
  • Samples No. 3 to No. 14 to which silica powder, silica sol or magnesia powder were added as a sintering additive to the first support layer exhibit an increase in the fracture strength in comparison to Samples No. 1 and No. 2 to which a sintering additive was not added to the first support layer.
  • a sufficient fracture strength was imparted to Samples No. 10 and No. 11 in which the thickness of the first support layer was 150 micrometers.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
EP15763806.5A 2014-03-28 2015-03-10 Monolithic separation membrane structure and method for producing same Active EP3124098B1 (en)

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JP2006212551A (ja) * 2005-02-04 2006-08-17 Hitachi Zosen Corp フィルター材及びその製造方法

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JPS63197510A (ja) * 1987-02-10 1988-08-16 Ngk Insulators Ltd セラミツクフィルタ
DE10125814C1 (de) * 2001-05-26 2002-07-25 Daimler Chrysler Ag Metall-Keramik-Verbundwerkstoff und Verfahren zu dessen Herstellung
JP2003230822A (ja) * 2002-02-08 2003-08-19 Ngk Insulators Ltd 多孔質フィルタ及び浄水器、並びにフィルタの検査装置及び方法
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CN106102877A (zh) 2016-11-09
JPWO2015146571A1 (ja) 2017-04-13
EP3124098A1 (en) 2017-02-01
MY182013A (en) 2021-01-18
EP3124098A4 (en) 2017-11-29

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